Flame resistant polymers containing amide complexes of metal salts

ABSTRACT

FLAME RESISTANT POLYMERS, SUCH AS HALOGENATED POLYESTERS AND POLYVINYL CHLORIDE CONTAINING AMIDE COMPLEXES OF CERTAIN METAL SALTS SUCH AS ZINC CHLORIDE-DIMETHYL FORMAMIDE, AND ARTICLES SUCH AS MOLDED BODIES, FILMS, ETC. OF SUCH FLAME RESISTANT POLYMERS.

United States Patent Oflice 3,705,123 Fatented Dec. 5, 1972 ABSTRACT OF THE DISCLOSURE Flame resistant polymers, such as halogenated polyesters and polyvinyl chloride containing amide complexes of certain metal salts such as zinc chloride-dimethyl formamide, and articles such as molded bodies, films, etc. of such flame resistant polymers.

BACKGROUND OF THE INVENTION Complexes of various metal salts with amides are reported by S. I. Kuhn et al., Canadian J. Chemistry, 43, 375 (1965), by M. A. J. Jungbauer et al., Nature, 202, 290 (1964), by M. Glavas et al., 1. Inorganic and Nuclear Chemistry, 31, 291 (1969), and by W. E. Bull et al., Inorganic Chemistry, 2, 303 (1963). Spectroscopic, thermal, and electrochemical data were developed to help elucidate the structure of these complexes. British Pat. 774,956 discloses iron salt complexes with a variety of amides for use as organic soluble carbonylation catalysts.

Antimony, tin and zinc oxides have been used as flame retardants in the presence of halogenated compounds. A number of borates, such as zinc borate, also are known flame retardants. These metal oxides and borates, however, are quite insoluble in most organic systems, producing pigmentation and opacity in articles containing them. Therefore, they are unsuitable for use where high levels of light transmission are required.

The halides of metals such as antimony, tin and zinc are also known to be flame retardants (Modern Plastics, p. 102, September 1966). These salts, however, have a tendency to degrade many polymeric systems and thus their use as flame retardants is quite limited. For example, zinc chloride causes severe discoloration and loss of strength in halogenated polyesters.

SUMMARY OF INVENTION This invention relates to flame resistant polymers containing amide complexes of certain metal salts in an amount to impart flame retardancy to the polymer. Preferred polymers are halogenated polyesters and polyvinyl chlorides. Articles formed from such flame resistant polymers have greater clarity and strength than can be obtained when metal salts are used alone to impart flame retardancy.

As a means of incorporating the amide complexes into the polymer, the complexes can be dispersed as a solid in the molten polymer or prepolymer or they can be dis solved with the polymer or prepolymer in a mutual solvent. In general, the level of amide complex in the polymer will range from 0.5 to 30% by weight. The amide, complexes can be used with other flame retardants such as phosphorous and antimony compounds.

DETAILED DESCRIPTION OF INVENTION The complexes useful for purposes of the invention can be illustrated by the following formula:

where M is boron, aluminum, iron, zinc, lead, tin or antimony;

X is chlorine, bromine, or iodine;

a is an integer in the range of from 2-5 such that the salt MX is neutral;

R is hydrogen, alkyl of 1-3 carbon atoms, or

Rs wherein R, is hydrogen or alkyl of 1-3 carbon atoms and R is hydrogen, alkyl of 1-3 carbon atoms, phenyl, bromo or chlorosubstituted phenyl; R and R are each hydrogen or alkyl of 1-3 carbon atoms;

and b is 1 or 2;

with the proviso that R and R can be joined together to form the group (CH wherein rz=34 and with the further proviso that R and R can be joined together to form the group (CH wherein n-=2-5 or can be taken together with the nitrogen atom (N) to form a morpholino group.

Exemplary of the complexes useful for the invention are those listed below. In this listing and throughout the specification the abbreviations DMF, DMAC, and NM? mean N,N-dimethylformamide, N,N-dimethylacetamide, and N-methylpyrrolidone, respectively.

ZnCl 2D MF ZnCl ZDMAC ZnCl ZNMP SnCl lDMF SbCl3 lDMF BBr lDMF BCl lDMF AlCl lDMF SnCl, 2DMF SbCl lDMF FeCl 2DMF ZnI 2DMF SnCl, 2DMF SbCl lDMF Pbl lDMAC ZnCl 2 (N,N-dimethylpropionamide) ZnCl 2 (N,N-diethylformamide) ZnCl 2 3 ,4-dichlorophenyl-1, l-dimethylurea ZnCl 2 l-acetylpiperidine) ZnCl 2( l-formylmorpholine) ZnCl 2 l-formylpyrrolidine) ZnCl 2 (3 ,4-dichlorophenyll l-dimethylurea) ZnCl 2 (4-chlorophenyl-1, l-dimethylurea) The amide complexes of the invention can be prepared according to the methods of S. I. Kuhn et al., Canadian J. Chemistry, 43, 375 (1965), W. E. Bull et al., Inorganic Chemistry, 2, 303 (1963), and U.S. Pat. 3,297,425.

The preferred polymeric materials are halogenated polyesters and polyvinyl chloride. Examples of suitable halogenated polyesters are given in RC. Nametz, Industrial and Engineering Chemistry, vol. 59 (1967), pages 99-116. Further examples of suitable halogenated polyesters are described in US. Pat. 2,810,712 and US. Pat. 3,536,781 which may be characterized as halogenated unsaturated polyesters derived from a halogenated unsaturated polycarboxylic acid and a polyol.

The term polyvinyl chloride as used herein is intended to include polymers and copolymers of vinyl chloride and compositions containing such a polymer or copolymers in combination with a plasticizing agent to increase the polymer or copolymers workability or flexibility.

Examples of plasticizing agents can be found in Modern Plastics Encyclopedia, 1970-71, pages 856-867. The manner of using such plasticizers, the properties imparted by their use and the mechanism involved are reviewed in ciently high in halogenated polyesters and polyvinyl chloride so that flame retardant articles can be made having a high degree of clarity.

The flame resistant polymers of the invention can con- Encyclopedia of Polymer Science, 2nd edition, vol. 10, 5 tain, in addition to the amide complexes, other tflame pages 228-306. retardant compounds such as antimony oxide, zinc borate,

Other polymeric materials which can be made flame tricresylphosphate, or alumina hydrate. resistant with the amide complexes include polypropylene, Both the metallic and amide portions of the complex polyvinylidene chloride, polymethylmethacrylate, polypresent in the flame resistant polymers of the invention esters, polyurethanes, polystyrene, styrene-acrylonitrile can be identified by relatively simple analytical methods. copolymers, epoxy resins, acrylonitrilebutadiene-styrene The method used for the metallic species is X-ray fluoresterpolymers, formaldehyde polymers, polycarbonates, cence spectroscopy. This method is discussed by I. M. polyvinyl alcohol, polyvinyl acetate, urea-formaldehyde Kolthoif, P. J. Elving, and E. B. Sandell in Treatise on polymers and phenol-formaldehyde polymers. Analytical Chemistry, vol. 5, John Wiley & Sons, New

If the polymeric material does not inherently contain York (1964); particularly in Part 1, Section D-3, Chaphalogen, the amide complex should be added with a mateter 60. It is also discussed by H. A. Liebhassky, X-ray rial which provides a source of halogen in order to give Absorption and Emission in Analytical Chemistry, John effective flame retardancy. The halogen source preferably Wiley and Sons, New York (1960). is a highly chlorinated or brominated material, such as The method used for the amide portion is mass spec- Chlorowax 70 (a chlorinated hydrocarbon wax supplied troscopy. The flame retarded polymer is ground into a by Diamond Shamrock Company) provided it is comfine powder. A sample Of the powder is placed in a sample patible with the particular polymer system in the proportube in the mass spectrometer. The temperature of the tions it is used. sample probe is gradually raised until mass peaks are In general, the amount of amide complex which is observed. The sample can be irradiated With from 15 to added to the polymeric material to impart flame retard- 80 e.v. and the amide identified by its fragmentation patancy will be in a range of from 0.5 to by weight. tern and molecular ion. The American Petroleum Insti- Below 0.5% little improvement in flame retardancy is we reference spectre can be used to p in he obtained. Above 30% added improvements in flame reanalysis Of the Spectrum API Reference Spectrum tardancy are small and the deterioration of other prop- 1133 is for MF- rties f th polymeric m teri l i apt t occur, Th 30 The following examples will serve to further illustrate preferred level of mid complex i th polymer i i the invention. In these examples all percentages are weight the range of from 1 to 10% by weight. percent. The HLT-15 flammability test method referred The amide complexes can be incorporated into the to is described y McMahon at 25th Annual polymer by mixing the dry powders with the powdered or Technical Conference (1970), Reinforced Plastics/Commelted polymer using any of the techniques currently used 35 Posites Division of the Society of the Plastics Industry, in the art for mixing antimony oxide or other solid pigin Section Pages ment or filler with polymeric materials for extrusion or blow molding. Alternatively, the complexes can be dis- EXAMPLES 1-5 solved with the polymeric material in a mutual solvent Such as -dimethylformamide. The complexes useful in the invention are synthesized If desired, the amide complexes can also be mixed with by dissolving the metal halide in excess amide solvent. prepolymers prior to hot pressing and casting operations. The excess solvent is then stripped at -l00 C. and Flame retarded, reinforced polyester panels having high 1-10 mm. of mercury, leaving the crude residual comhght transmission can be produced this way. plex. The complexes can be recrystallized or used in the As the molecular weight of the amide portion of the 45 crude form. The. complexes, melting points, recrystallizacomplex 1ncreases, the organic solubility of the complex tion solvent and infrared and nuclear magnetic resonance increases. As the solubility increases, the light transmisspectroscopic data are shown in Table I. Data on N,N-di- S1011 of polymeric materials containing the amide commethylformamide, N,N-dimethylacetamide, and N-methplex increases. The solubility of the complexes is sufliylpyrrolidone are given for comparison.

TABLE I Recrystallization LB (V) NMR Example Complex M.P. solvent 0:0 N--C=0 N-OH;

1 ZnClz-ZDMF 113-114 Oyclohexanone 1,640 689 2. E3 2. 43 0 7.62 (H( 3) 2 ZnCIz-2DMAC..'.'.-..-.'.-..1. -117 Diehloromethane... 1,599 745 3.20 3.10 O

2. 40 (OHu i-o 3.- ZnCh-ZNMR...;.; 64-66 (lyclohexanonenu'u 1, 630 2. 99 3-58 (0:55), 2.82 and -245 (CzHa and C4112) 4 SHCIZ'IDMF 67-69 do 1,635 675 3.25 3.08 0

8. 40 (H-("]-) 6-. SbC1a-1DMF...'.'...-'..'..'....;..:.;.-;.;.;'.; 1,635 -660 3.18 3.00 O

8.18 (H(%-) N,N-dimethyliormamlde...-- 1,660 2. 53 2. 43

7.62 (H- N,N-dimethylaeetamide.-..:...;;:.:-;-.;.:. 1,630 730 3.07 2.97

2.08 (OHid N-methylpyrrolidone 1,670 2. 85 3. 42 can 2. 55-1. 62 (C Hz-CtI-L) l Subscript on carbon indicates the ring position and not the number of carbons.

EXAMPLE 6 A flame retarded plasticized polyvinyl chloride film is made by mixing the following ingredients and casting them into a film.

- Percent Pliovic S-51 (a polyvinyl chloride resin supplied by Goodyear Rubber Co.) 25.0 Dioctylphthalate 17.5 SnCl lDMF 2.7 DMF 54.8

The film cast from this solution is dried at 120 C. for 20 minutes. A slightly delustered, light yellow, flexible film is produced which is self-extinguishing, and nondripping in a vertical match test. A similar film without the SnCl -1DMF burns and drips in this test.

EXAMPLE 7 A flame retarded, plasticized polyvinyl chloride film is made by mixing the following ingredients, and casting them into a film.

Percent Pliovic S-5l 25.2 Dioctylphthalate 17.6 SnCl EDMF 2.8 Antimony (V) triglycoxide 3.1 DMF 51.3

The film cast from this solution is dried at 120 C. for 20 minutes. A slightly delustered, light pink, flexible film is produced which is self-extinguishing, and nondripping in a vertical match test.

EXAMPLE 8 A flame retarded, plasticized polyvinyl chloride film is made by mixing the following ingredients, and casting them into a film.

Percent Pliovac S-51 25.0 Tricresylphosphate 17.5 SnCl lDMF 2.7 DMF 54.8

The film cast from this solution is dried at 120 C. for 20 minutes. A lusrous, light yellow, flexible film is produced which is self-extinguishing and nondripping in a vertical match test.

EXAMPLE 9 A 8" x 7" x Vs" polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Hetron 23925 (a polyethylenechlorendate/styrene polyester supplied by Hooker Chemical Co.) 94.4 ZnCl -2DMF 4.7 Benzoyl peroxide 1.0

The Hetron 23925 resin and the ZnCl -2DMF are mixed for 30 minutes at 35-42 C., and then the benzoyl peroxide is added. The mixture is stirred for an additional 20 minutes before pouring it into a 8" x 7 x A" mold at 45-50 C. The mold is placed in a hot press with 29,000 psi. on the 2.56 in. diameter (6.50 cm.) piston, and heated according to the following schedule.

Time, mins.: Temperature 15 79 C. (175 F.) 20 107 C. (255 F.) 20 135 C. (275 F.)

Another panel having hydrated zinc chloride in place of the ZnCl -2DMF is opaque, yellow and very weak.

EXAMPLE 10 A 8" x 7" x polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Dion FR6399 (a polyethylene-5-norbornene-2,3- dicarboxylate (partially brominated)-styrene supplied by Diamond Shamrock Co.) 96.6 ZnCl -2DMF 2.4 Benzoyl peroxide 1.0

The ingredients are mixed and hot pressed according to the conditions described in Example 9. The resulting panel is crystal clear, and has an HLT-15 flammability rating of 100.

A similar panel without the ZnCl -2DMF is crystal clear, and has an HLT-15 flammability rating of 80.

Another panel having hydrated zinc chloride in place of the ZnCl -2DMF is red, tacky, and weak.

EXAMPLE 11 A 8" x 7" x polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Hetron 23925 94.2 ZnCl -2DMF 4.9 Benzoyl peroxide 1.0

The ingredients are mixed and hot pressed according to the conditions described in Example 9. The resulting panel is almost completely clear, and has an HLT-15 flammability rating of 85.

EXAMPLE 12 A 8" x 7" x A3" polyester panel is made according to Example 11 using Dion FR6399 in place of the Hetron 23925.

The resulting panel is almost completely clear and has an HLT-15 flammability rating of 100.

EXAMPLE 13 A 8" x 7" x A" polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Hetron 23925 91.7 ZnCl -2NMP 7.4 Benzoyl peroxide 0.9

The ingredients are mixed and hot pressed according to the conditions described in Example 9. The resulting panel is crystal clear and has an HLT-15 flammability rating of 92.

EXAMPLE 14 A 8" x 7" x A" polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Dion FR6399 96.2 ZnCl -2NMP 2.9 Benzoyl peroxide 1.0

The ingredients are mixed and hot pressed according to the conditions described in Example 9. The resulting panel is crystal clear and has an BLT-15 flammability rating of 100.

EXAMPLE 15 A 8" x 7" x Ms" polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Hetron 23925 93.4 Antimony trioxide 1.0 ZnCl- 2DMF 4.7 Benzoyl peroxide 1.0

EXAMPLE 16 A 8" x 7" x /e" polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Dion FR6399 93.5 Antimony trioxide 0.9 ZnCl 2DMF 4.7 Benzoyl peroxide 0.9

The ingredients were mixed and hot pressed according to the conditions described in Example 15. The resulting panel is opaque, and has an HLT-lS flammability rating of 100.

EXAMPLE 17 A 8" x 7" x polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Hetron 23925 92.5 Antimony '(V) triglycoxide 1.9 ZnCl -2DMF 4.6 Benzoyl peroxide 0.9

The ingredients are mixed and hot pressed according to the conditions described in Example 15. The resulting panel is highly translucent and has an HLT-15 flammability rating of 100.

A similar panel without the antimony glycoxide has an HLT-l flammability rating of 92. Another panel without the ZnCl -2DMF has an HLT-l5 flammability rating of 60.

These data indicate a synergism between the antimony (V) triglycoxide and the ZHCIQ'ZDMF- EXAMPLE 18 A 8" x 7 x /s" polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Dion FR6399 96.4 ZnCl -2DMF 2.4 Antimony (V) triglycoxide 0.3 Benzoyl peroxide 1.0

The ingredients are mixed and hot pressed according to the conditions described in Example 15. The resulting transparent panel is almost entirely free of crystals, and has an HLT-lS flammability rating of 100.

EXAMPLE 19 A 8" x 7" x AV polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Dion FR6399 95.2 SbCl -1DMF 2.8 Benzoyl peroxide 1.9

8 EXAMPLE 20 A 8" x 7" x /e" polyester panel is made by mixing formulations A and B in a 1: 1 ratio.

Formulation A: Percent Hetron 23925 89.3

8.9 ZnCl -2DMF 8.9 Benzoyl peroxide 1.8

Formulation B: Percent Hetron 23925 99.6 N,N-diethylaniline 0.4

Formulations A and B are made by mixing the ingredients at 35 C. for /2 hour. Then the formulations are mixed together and placed in a 8" x 7" x Ms" mold. In about /2 hour the mixture begins to gel, and the completed panel is removed from the mold in about 1 hour.

The resulting panel is similar to the one made in Example 9.

EXAMPLE 21 A 8" x 7" x Va" polyester panel is made by mixing the following ingredients and hot pressing them.

Percent Dion FR6399 96.2 ZnCl -2-Urea 2.9 Benzoyl peroxide 1.0

The ingredients are mixed and hot pressed according to the conditions described in Example 9. The resulting panel is highly translucent, although it contains some crystals. It has an HLT-15 flammability rating of 100.

What is claimed is:

1. A flame resistant composition of matter consisting essentially of a polymeric material selected from the group consisting of halogenated unsaturated polyester derived from a halogenated unsaturated polycarboxylic acid and a polyol and polyvinylchloride and from 0.5 to 30% by weight, based on said polymeric material, an amide complex of the formula:

I (X) rb(BrilN where M is boron, aluminum, iron, zinc lead, tin or antimony; X is chlorine, bromine, or iodine; a is an integer in the range of from 2-5 such that the salt MX is neutral; R is hydrogen, alkyl of 1-3 carbon atoms, or

where R, is hydrogen or alkyl of l-3 carbon atoms and R is hydrogen, alkyl of 1-3 carbon atoms, phenyl, bromo or chlorosubstituted phenyl; R and R are each hydrogen or alkyl of 1-3 carbon atoms; and b is 1 or 2; with the further proviso that R and R can be joined together to form the group -(CH wherein n=25 or can be taken together with the nitrogen atom (N) to form a morpholino group.

2. A composition of claim 1 wherein the polymeric material is a halogenated polyester.

3. A composition of claim 1 wherein the polymeric material is polyvinyl chloride.

4. A composition of claim 1 wherein the amide complex is ZnCl -2-dimethyl formamide.

5. A composition of claim 1 wherein the amide complex is snCl -dimethyl fornamide.

6. A composition of claim 1 wherein the amide complex is ZnCl -2(3,4-dichlorophenyl-l,l-dimethylurea).

7. A composition of claim 1 wherein the polymeric material is a halogenated polyester, the amide complex is ZnCl -b-dimethy1 formamide where b is 1 to 2, and the 5 amount of amide complex is from 1 to 10% by weight based on the polymeric material.

8. A shaped article of the composition of claim 7.

9. A composition of claim 1 wherein the polymeric material is polyvinyl chloride, the amide complex is Mcl -b-dimethyl formamide where M is Zn or Sn and b is l to 2, and the amount of amide is from 1 to 10% by weight based on the polymeric material.

10. A shaped article of the composition of claim 9.

10 References Cited UNITED STATES PATENTS 1,867,658 7/1932 Dreyfus 117136 2,838,424 6/1958 Depew et a1. 117137 3,239,482 3/1966 Rapp 26045.75

DONALD E. CZAJA, Primary Examiner V. P. HOKE, Assistant Examiner U.S. Cl. X.R.

2602.5 FP, 2.5 A], 45.75 K, 45.8 R, 45.8 N, 45.9R 

